Mold Positive Design

From escalation with the last design and experimentation, I decided to keep a similar, more simplistic form. A big challenge was getting into the mindset of positives vs. negatives and making sure the structure is correct, alongside being very conscious of draft angles and release. I thought choosing a rounder, smoother object would make that simpler, but even through modifications from the first iteration it was still challenging. I used the DraftAngleAnalysis command to identify smaller, less obvious areas that could cause release issues or undercuts, and adjusted the form accordingly.

As can be seen through experimentation, I was initially having trouble wrapping my head around getting a two-piece mold strategy to work (and successfully showing a positive, the mold/negative, and the final object). I initially made a single-part, open-faced mold again for simplicity, and because I couldn’t successfully create the two-piece at first. I’m keeping the one-piece version as a backup option and learning reference, since it’s a lower-risk approach if time gets tight. Through trial and error (and some stubbornness), I eventually managed to build the two-piece mold, which I prefer if it works, because it better showcases my original design without compromise (avoiding the need for one flat side). The main risks I anticipate with the two-piece mold are alignment/seam lines and potential leaks, so registration and clamping/banding the mold halves consistently will be important.

*In attached images pink = positive forms (which will be the foam), beige = negatives (mold), and blue = final object*